Drill Rig Safety
Brian Stringer
Former BDA National Secretary
British Drilling Association
BDA ‘Driving Site Safety’ Seminar
Manchester United FC
9th April 2014
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Protection against Rotating Parts
Biggest Drill Rig Safety Issue
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Protection against Rotating Parts
• Known as “The Guarding Issue”
• Active in UK since 1999
• UK’s Health & Safety Executive (HSE)
called a meeting of the Drilling & Piling
industries in April 1999
• BDA & FPS Guidance
Aug/Sept 2000
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Protection against Rotating Parts
• HSE’s authority was derived from:
• Regulation 11 of PUWER 98
(Provision and Use of Work Equipment Regulations
1998 amended 2002)
• This applies to Users of Equipment
• All recent UK Regulations are derived from
European Community Directives
• Originally Machinery Directive 98/37/EC
(now 2006/42/EC)
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Protection against Rotating Parts
• Manufacturing / selling equipment in
UK
• Have to comply with:
• The Supply of Machinery (Safety)
Regulations (2008 amended 2011)
• Derived from:
• Machinery Directive 2006/42/EC
• Essential Health & Safety Requirements
(EHSRs) interpreted by EN Standards
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Protection against Rotating Parts
SUMMARY SO FAR
• One Regulation for Users
• Another for Manufacturers / Suppliers
• BUT BOTH DERIVE FROM EUROPEAN
MACHINERY DIRECTIVE (which is
mandatory on all EU governments)
• And Directive calls up
• EN (ISO) STANDARDS
(Note that EN791 Drill Rig Safety 1995 precedes 1998
and 2006 Machinery Directives)
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Protection against Rotating Parts
6.1
REGULATION 11 DANGEROUS PARTS OF
MACHINERY
(1)
Every employer shall ensure that measures are
taken in accordance with paragraph (2) which
are effective –
(a) to prevent access to any dangerous part of
machinery or to any rotating stock-bar
or
(b) to stop the movement of any dangerous part of
machinery before any part of a person enters a
danger zone.
PUWER as amended 2002
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Protection against Rotating Parts
• First requirement
• TO PREVENT ACCESS
or
• TO STOP MOVEMENT
before people enter danger zone
(Once entanglement starts it’s too late)
• BUT NEXT REQUIREMENT FOLLOWS
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Protection against Rotating Parts
(2) The measures required by paragraph (1) shall consist of (a) the provision of fixed guards enclosing every
dangerous part or rotating stock-bar where and to the
extent that it is practicable to do so, but where or to the
extent that it is not, then
(b) the provision of other guards or protection devices
where and to the extent that it is practicable to do so, but
where or to the extent that it is not, then
(c) the provision of jigs, holders, push-sticks or similar
protection appliances used in conjunction with the
machinery where and to the extent that it is practicable to
do so,
and the provision of such information, instruction, training and
supervision as is necessary.
PUWER as amended 2002
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Protection against Rotating Parts
• “SHALL” is mandatory (Should, must, can
etc. are not)
• “PRACTICABLE” is legal term. If it’s
technically possible it shall be done
regardless of cost. (Prior to 1998 the words
“reasonably practicable” were used.)
• “HIERACHY” Start at the top and work down
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Protection against Rotating Parts
UK History
• 1999 HSE raise the issue
• 2000 BDA & FPS publish guidance
• Guidance allows slow rotational mode
• 2000 – 2006
- Awareness developing
- Some contractors take action & fit guards
- Fears of loss of production, loss of
visibility, cost, change in working practice
etc.
- Manufacturers less than supportive
- Retro fitting the problem
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Protection against Rotating Parts
UK History
• March 2004 severe entanglement
• April 2006 HSE prosecute
• £50,000 fine
• Industry wakes up
Driller’s glove
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Protection against Rotating Parts
UK History
• 2006 onwards – HSE raise the game
• BDA circulates information and encourages
compliance
• More entanglement accidents (abroad as
well)
• BDA works with HSE to clarify exact
requirements e.g. interlocked guard
• Contractors put pressure on manufacturers /
suppliers who respond
• Contractor fears largely disappear
(not proven in practice apart from cost)
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Protection against Rotating Parts
UK History
• 2009
- HSE turns the screw more (prohibition
notices)
- Has been a culture change
- Vertical drilling in open air (all sides agree
that it’s interlocked guarding)
- BDA / HSE
Inclined Drilling
Guidance May 2009
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EN 791 Drill Rigs – Safety - Revision
EUROPE (EU countries)
-28 Countries
-500 + million people
-3rd biggest after China
and India
-Germany 83 million
-France 63 million
-UK 61 million
-Italy 59 million
-Spain 44 million
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EN 791 Drill Rigs – Safety - Revision
• EU Directives state legal objectives
• “Harmonised” EN Standards identify
technical means to meet legal objectives
• 3 classes of EN Standard
- A-type, basic methodology - only 2, of
which EN ISO 12100 (2010) is most important
- B-type, common to all e.g. Noise
- C-type, specific class of machines e.g drill
rigs have EN 791, piling rigs have EN 996
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EN 791 Drill Rigs – Safety - Revision
EN 791 1995 (November)
BS EN 791 1996 (June)
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EN 791 Drill Rigs – Safety - Revision
• CEN is European Standards body
• CEN TC 151 (Technical Committee), WG3 (Working
Group 3) looks after drilling, and includes WG2,
piling)
• Has been revising EN 791 & 996 (Piling)
• France, Germany, Italy,
Sweden, Finland, UK + +
• Started revision Feb 2008
• EU Public vote Feb 2014
• 97% acceptance
• New EN Standard April 23rd 2014
• New BS Standard by 23rd October
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EN 791 Drill Rigs – Safety - Revision
• CEN TC 151 (Technical Committee)
relationship to BSi
• BSi ‘mirror’ committee is B/513 (Construction
equipment and plant and site safety)
• B/513/02 is working group for Drilling, piling
and tunnelling
• B/513/02 sent UK Experts to CEN TC 151,
WG3
Variously Donald Lamont (HSE); Ian Simpson
(HSE); Brian Stringer (BDA); Keith Bolton
(FPS); Bob Storey (BSP)
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EN 791 Drill Rigs – Safety - Revision
• EN 16228 Drilling and foundation equipment
– Safety
(is in 7 Parts)
•
•
•
•
•
•
•
Part 1: Drilling and foundation equipment – Safety – Common
requirements
Part 2: Drilling and foundation equipment – Safety – Mobile drill rigs
for civil and geotechnical engineering, quarrying and mining
Part 3: Drilling and foundation equipment – Safety – Horizontal
directional drilling equipment (HDD)
Part 4: Drilling and foundation equipment – Safety – Foundation
equipment
Part 5: Drilling and foundation equipment – Safety – Diaphragm
walling equipment
Part 6: Drilling and foundation equipment – Safety – Jetting, grouting
and injection equipment
Part 7: Drilling and foundation equipment – Safety – Interchangeable 20
auxiliary equipment
EN 16228 Drill Rigs – Safety – Revision
CEN TC 151 WG3
Most contentious issues
• Protection against moving parts
• Stability calculations
• Noise
• Interchangeable auxiliary equipment
• Performance levels – safety functions
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EN 16228 Drill Rigs – Safety – Revision
Stability Calculations
• EN791 & 996 Conflict
• EN791 more conservative
• Piling rigs grown taller
• User – greater depth requirement (mast
height), less chance of overturning
• Manufacturer – engineering limits, user take
more responsibility for ground conditions
TOOK LONG TIME TO RESOLVE
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EN 16228 Drill Rigs – Safety – Revision
Noise
• European Outdoor Directive
• Drill Rigs – noise marking only (no limit)
• Moving in direction of noise limits
• Drilling process generates noise
• How to measure?
• Percussive / Rotary Percussive rock test
(Part 2)
CEN NOISE CONSULTANT VERY PARTICULAR
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EN 16228 Drill Rigs – Safety – Revision
Interchangeable Auxiliary Equipment
• Part 7
•
“includes pile installation and extraction equipment, impact hammers,
extractors, vibrators, deep vibrators, static pile pushing/pulling
devices, rotary percussion hammers, rotary drilling drives, drill mast
equipment such as leaders equipped with a drill stem and gears
attached to the boom of an excavator, casing oscillators/rotators”
• Down Hole Hammers have to be engraved
• Could have included corebarrels etc.
• Very little written at end of day
WAS AN AFTERTHOUGHT AND CONFUSING TO DEAL WITH
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EN 16228 Drill Rigs – Safety – Revision
Performance levels – safety functions
• A REQUIREMENT TO ‘GRADE’ ALL SAFETY
RELATED PARTS OF CONTROL FUNCTIONS
• Is a table in Part 1 to conform to EN 13849-1
• Debates about grade levels for interlocked
guards etc.
USERS WANTED HIGHER GRADES
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EN 16228 Drill Rigs – Safety – Revision
Protection against moving parts
• “Where access to moving parts directly involved in
the drilling and piling process is foreseeable during
normal operation of the machinery, safeguards shall
be selected from the following:
 Fixed guard or;
 interlocking movable guard with or without guard
locking or;
 sensitive protective devices, e.g. electro-sensitive
protective equipment or pressure sensitive devices
or;
 a combination of the above.”
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EN 16228 Drill Rigs – Safety – Revision
Protection against moving parts
•
“When the interlocking movable guard is opened, the rotation and
feed functions together with any associated moving parts identified
with residual risks shall stop. Restarting with an open interlocking
movable guard shall only be possible in restricted operating mode”
• “Restricted operating mode shall comprise:
 A rotational speed of not more than 30 rpm or “inching mode” that is
no more than half a revolution per activation in the danger zone and;
 a feed speed of not more than 15 m/min, or “inching mode” that is no
more than10 cm feed stroke per activation, in the danger zone and;
 “hold-to-run” control for rotation function and;
 “hold-to-run” control for feed function and;
 an indicator informing the operator and crew that the restricted
operating mode is on.
When hold to run controls for rotation are released the rotating parts
shall stop in less than half a revolution.”
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EN 16228 Drill Rigs – Safety – Revision
Protection against moving parts
• Fixed, Interlocking Movable Guards and “Restricted
Operating Mode” are familiar to us in UK
BUT THE STANDARD ALLOWS
• Sensitive protective devices
• Special protective mode for specific circumstances
• Exemptions in Part 2 (Drill Rigs)
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EN 16228 Drill Rigs – Safety – Revision
Protection against moving parts
• “Sensitive protective devices shall detect foreseeable
access to the rotating parts danger zone, during any dangerous
movement. When the sensitive protective device is activated,
the rotation and feed functions together with any moving parts
identified with residual risks shall stop.”
• EN 12100-1 “equipment for detecting persons or parts of persons
which generates an appropriate signal to the control system to
reduce risk to the persons detected. The signal may be generated
when a person or part of a person goes beyond a predetermined
limit – e.g. enters a hazard zone – (tripping) or while a person is
detected in a predetermined zone (presence sensing), or in both
cases”
ARE WE STILL ALLOWING TRIP WIRES? ITS NOT CLEAR.
“e.g. electro-sensitive protective equipment or pressure sensitive devices”
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EN 16228 Drill Rigs – Safety – Revision
• Are these Protective Devices?
(See EN ISO 12100-1 for definition)
Multiple E stops
Emergency stop
Trip wires
Toggle switches
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Pressure plates
EN 16228 Drill Rigs – Safety – Revision
Protection against moving parts
• “Special protective mode for specific circumstances
– Where circumstances are foreseen by the manufacturer that
specific applications/positions/orientations where the use of
safeguards (guards and protective devices) is not possible (e.g.
confined spaces, limited working areas, work close to
obstacles or structures), a special protective mode shall be
installed to operate without guards and sensitive protective
devices disabled.”
•
“Rotation and feed controls shall be hold-to-run; rotation and feed can
operate at normal speed; a warning signal (visual and/or audible) shall
be activated when the special protective mode is selected; additional
pressure sensitive devices shall be fitted.”
THIS IS OPEN TO ABUSE BY USERS WHO COULD TAKE
OFF GUARDS AND DISABLE PROTECTIVE DEVICES
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EN 16228 Drill Rigs – Safety – Revision
Protection against moving parts
• Exemptions in Part 2 (Drill Rigs)
• Underground pre-armouring
machine
• Drill Jumbo
HOWEVER ADDITIONAL SAFEGUARDS E.G. MOTION
DETECTORS ETC. TO BE FITTED
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EN 16228 Drill Rigs – Safety – Revision
Protection against moving parts
THE FUTURE ?
• Digital cameras
configured to detect
movement
• Defines dangerous
working area
• When people enter
- drilling immediately
stops
- safety procedure
activated (rotation/feed
slow mode)
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EN 16228 Drill Rigs – Safety – Revision
WHAT NEXT?
• Manufacturers to use EN 16228 from April /
October 2014
• BS EN 791 / 996 withdrawn by Oct 2014
• Europe sorted – What about the world?
• Currently no ISO Standard
• Vienna Convention EU – ISO Co-operation
• Proposal at May 2014 ISO/TC 195 China
meeting (Secretary & Convenor are CEN !!) 34
THANKS FOR LISTENING
NOW OPEN FOR QUESTIONS
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